Behind the Scenes II: Laser Fabrication

Since 2019, Cadence, a manufacturer of critical components and assemblies for Minimally Invasive Surgery (MIS) applications, is represented by MedNet on the European market. Founded in the USA in 1985 as a sharps manufacturer, today Cadence employs over 575 people and is a full-service provider for metals and plastics fabrication along with an industry leading CNC sharpening capability. Join us "behind the scenes" of our new partner: In the second series we are showcasing Cadence's capabilities for laser fabrication.

Laser Fabrication

Laser processing has become a fundamental manufacturing step for many new products. As a vertically integrated manufacturer Cadence provides various state-of-the-art laser technologies to optimize production output, to customize fabrication to customers’ needs and to meet unique industry challenges, like high precision and repeatability for critical medical components. As such, Cadence continues to develop and invest in laser processing technologies to meet the ever-changing needs of new product development.

Precision Laser Drilling

Cadence offers consistently precise, reliable, high-quality welds for a wide range of materials for medical device components and subassemblies, as well as many other applications. With more than 3 million complex laser welded assemblies produced every year, Cadence is one of the leading welding partners in the industry. Using the latest technologies, Cadence can perform precise laser welding at great speed and efficiency, as well as repeatability. Via spot or seam welds Cadence can join not only similar but also dissimilar metals. Thus resulting in welds that provide excellent strength and visual appearance.

Dual-beam technology (weld on opposite sides of a part at the same time)

Double-closed loop power control (Pulse-to-pulse stability of less than 1% yields; better joints and less variation)

5-axis control

Spot sizes from 0.001″ to .04" (0,0254mm to 1,016mm)

Cleanroom laser welding

Benefits over conventional technologies

More consistent, reliable joints

Small heat-affected zone (HAZ)

Deep penetration of precise narrow weld

Narrow weld profile

Low heat input

Minimum part distortion

No to minimal secondary processes

High repeatability

Significantly faster weld rates

To provide the optimum weld you have to consider various circumstances and steps: the right focus of the laser, appropriate gas shielding, well-engineered joint design, ensuring repeatability, process variables such as correct type of laser for the material and thickness as well as reflectivity, conductivity and cleanliness of the material… — with its Advanced Welding LabTM Cadence integrates all these criteria into one unique, controlled process.

Precision Laser Drilling

The laser drilling process is an inexpensive alternative to mechanical drilling, and very adaptable for small holes with large depth to diameter ratios. Precision laser drilling provides a repeatable, accurate hole that can be customized for all types of manufacturing industries and gives consistency especially to those, who require tight tolerances. The process can provide dynamic changes of hole diameter, depth and edge quality. Shaped holes of almost unlimited geometry are now possible producing unique benefits previously unobtainable by conventional processing techniques.

Capabilities

Percussion Drilling is performed by repeatedly pulsing the focused laser energy at a material surface, vaporizing layer by layer.

For cylindrical parts Cadence offers Drilling On the Fly (DOF), where percussion holes are drilled while the part is in motion.

Laser Ablation

Cadence's laser ablation process is used in microfabrication to selectively remove material from a solid substrate through laser pulses. These short, laser beam pulses are controlled in a manner that removes material from a solid (or occasionally liquid) surface so quickly that the surrounding material absorbs very little heat, preventing thermal distortion in the base material.

Applications

3-dimensional ablating of PEEK for implants

Channel machining for microfluidic devices

Removing polyimide or parylene coating for catheters and guidewires

Marking fiducials or data metric codes on semiconductor wafers

Removing dielectric cover material to expose electrodes

Benefits

High precision tolerances

Fine surface finishes

Material removal rate controlled at nanometer scale

End result material is virtually burr-free

Small beam diameter to increase flexibility for microstructures and other engineered surface

No consumable tooling costs for electrodes, wire or cutters

Laser Marking

Cadence capabilities include light or deep marking, customized to meet the need of each application, e. g. tubes for instrument shafts can be laser marked with company names, descriptions, or incremental measurements. Cadence also develops and tests for passive marking on certain applications.

Adapted to critical components and complex sub-assemblies, Cadence’s equipment is optimized as follows:

improved image resolution

customized material handling for feeding sharps

laser marking in the same cycle as laser cutting and welding

either linear or rotary axis operations, automated or manual

LaserSwiss Machining

Cadence's LaserSwiss Machining capability combines 6-axis Swiss machining and laser cutting in one process and eliminates many manufacturing restrictions. You get the productivity of Swiss machining PLUS precise cuts from the laser cutter without having to move the part to another machine.

Multi-Axis Laser Cutting

Precision 4-axis and 6-axis cutting, tubing and hydroformed details

Laser processing of Stainless, Nickel, Titanium, and Aluminum

Experienced laser cutting of complex sheet metal details

Latest Fiber Laser technology with superior beam quality

Benefits

Lower costs

Less setup time

Better precision with less variation

Eliminates multiple setups and deburring operations

Threading, chamfering, and laser cutting achieved in seconds

Laser Cutting

Laser cutting is fast, flexible and cost-effective while providing a considerably better-finished result than other processes. In industries where precision is a high priority and quality is essential, it can be a tremendous production asset. It is a critical process needed for the manufacture of complex surgical device components.

Cadence’s laser cutting equipment is customized to the needs for surgical devices providing higher precision motion control and specific material handling such as automated coil feeding of flat stock and auto loading of tubing materials.